Method of making a plastic butterfly valve vane with peripheral seal

ABSTRACT

A method of making a vane for a butterfly valve or the like wherein the vane has a relatively rigid main body portion and a resilient sealing portion on the periphery of the body portion. A movable mold member is heated to a temperature at or above the temperature required to cause liquid elastomeric material to become solid upon contact therewith. The heated mold member is placed into the cavity of a mold having an edge surface which defines the outer periphery of a first mold portion with the periphery of the heated mold member spaced from the edge surface thereby defining the inner periphery of the first mold portion, the first mold portion having a configuration corresponding to the configuration of the sealing portion. Liquid elastomeric material is poured into the first mold portion and is partially cured until it becomes non-liquid and hence non-flowable. The heated mold member is removed to form a second cavity in the mold which is surrounded by the partially cured elastomeric material. Liquid thermosetting plastic material is poured into the second cavity of the mold such that it flows in contact with the inner periphery of the elastomeric material. A pivot rod may be placed on the mold in such a manner that the rod extends transversely of the mold and a portion of the rod is immersed in the liquid thermosetting plastic material. The mold with the partially cured elastomeric material, liquid thermosetting plastic material, and pivot rod therein is then exposed to curing temperature to solidify the thermosetting plastic material with the pivot rod embedded therein, and to complete curing of the elastomeric material.

[451 Aug. 26, 1975 l l METHOD OF MAKING A PLASTIC BUTTERFLY VALVE VANE WITH PERIPHERAL SEAL [75] Inventor: Phillip L. Rubright, Berkley, Mich.

[731 Assignee: Arco Industries Corporation,

Detroit. Mich.

[22] Filed: Sept. 8, I972 [2|] Appl. No; 287,293

Related US. Application Data [62] Division of Scr. No. 146,369, May 24, 1971.

[52] US. Cl. 264/255; 264/259; 264/26]; 264/267; 264/DlG. 60 [Si] Int. Cl..... 829C 5/00; 829C 5/l2; B29D 3/00 [58] Field of Search 264/250, 252, 259, 242. 264/271, 276, 279, DIG. 59, DIG. 60, 263, 275, 302, 255, 261, 267; 251/305, 306

[56] References Cited UNITED STATES PATENTS 2,663,908 l2/l953 Maier et al. 264/DIG. 59

2,665,52l l/l954 Ford 264/259 2,703.437 3/l955 Lindblad e 264/255 2,760,233 8/[956 Bjorkstcnn. 264/DIG. 59

2,934,823 5/l960 Preis 264/250 X 2,959,820 ll/l960 Miller et al. 264/3 l0 3,398,222 8/1968 Kaufman et al. 264/250 3,420,729 l/l969 Roberts 264/250 3,565,394 l2/l968 Smith 25l/306 3,655,861 4/1972 Roberts... 264/250 3,703,57l ll/l972 Roberts 264/334 Primary E.raminerR0bert F. White Assistant Examinerwillard E. Hoag Attorney, Agent, or Firm-Reising, Ethington & Perry |57| ABSTRACT A method of making a vane for a butterfly valve or the like wherein the vane has a relatively rigid main body portion and a resilient sealing portion on the periphery of the body portion. A movable mold member is heated to a temperature at or above the temperature required to cause liquid elastomeric material to become solid upon contact therewith. The heated mold member is placed into the cavity of a mold having an edge surface which defines the outer periphery of a first mold portion with the periphery of the heated mold member spaced from the edge surface thereby defining the inner periphery of the first mold portion, the first mold portion having a configuration corresponding to the configuration of the sealing portion. Liquid elastomeric material is poured into the first mold portion and is partially cured until it becomes non-liquid and hence non-flowable. The heated mold member is removed to form a second cavity in the mold which is surrounded by the partially cured elastomeric material. Liquid thermosetting plastic material is poured into the second cavity of the mold such that it flows in contact with the inner periphery of the elastomeric material. A pivot rod may be placed on the mold in such a manner that the rod extends transversely of the mold and a portion of the rod is immersed in the liquid thermosetting plastic material. The mold with the partially cured elastomeric material, liquid thermosetting plastic material, and pivot rod therein is then exposed to curing temperature to solidify the thermosetting plastic material with the pivot rod embedded therein, and to complete curing of the elastomeric material.

6 Claims, 8 Drawing Figures PATENTEU Amaze ms SHEET 1 BF 3 H, I! I ii! PATEHTEU BZ 5 I975 SIlZET 2 SF 3 METHOD OF MAKING A PLASTIC BUTTERFLY VALVE VANE WITH PERIPHERAL SEAL This application is a divisional of Application Serial No. M6369, filed May 24, l97l.

This invention relates generally to flow control devices such as valves, dampers and the like for controlling flow through a duct or other flow passage, and is particularly concerned with a flow control device suitable for use in air conditioning, heating and ventilation systems of automobiles, and to a method and apparatus for manufacturing such flow control devices.

Flow control devices in the form of dampers or butterfly-type valves are particularly suitable for controlling the flow through automobile ventilation, air conditioning and heating ducts due to the ease and speed with which such devices can be manipulated. One of the problems with such devices is that of obtaining a good seal when the flow control device is in a closed position to shut off flow through a particular duct. This problem is of course magnified when the ducts and flow control devices must be produced on a mass production basis so that economical tolerances can be maintained for both the ducts and the flow control devices commensurate with the requirements for interchangability of the parts. For large quantity production, it is of course also necessary to maintain production and material costs at a minimum.

A flow control device of this type must have a relatively rigid body portion to which mounting means such as a pivot rod or the like can be secured, and must have a peripheral resilient sealing portion for engagement with the inner walls of the duct being controlled by the flow control device. The conventional flow control device of this type includes a metal body with a resilient sealing member somehow attached to the periphery of the metal body, the metal body having a pivot rod or some other type of mounting means secured thereto for pivotally mounting the device in a duct or conduit. Such devices are expensive to manufacture since the metal parts must first be formed. cast, machined or the like, and then must have a resilient sealing member attached thereto.

Examples of prior art flow control devices of this type including some prior art methods of fabrication and manufacturing the same, are disclosed in US. Nos. 2,772,850; 2,983,478; 3,050,78 l; 3,l l L300; 3,l93,9l4; 3,272,904; and 3,447,222.

An object of this invention is to provide a method and apparatus for making, on a mass production basis, a flow control device such as a vane for a butterfly valve or the like, the vane having a relatively rigid main body portion with a resilient sealing portion and a mounting rod or the like embedded in the main body portion.

In carrying out the foregoing, and other objects, a flow control device according to the invention may be in the form of a vane for a butterfly valve or the like and include a main body portion of thermosetting epoxy resin to which is molded on the periphery thereof a sealing portion of elastomeric material. The sealing portion may he of vinyl plastisol.

The main body portion may have embedded therein a mounting rod for pivotally supporting the device in a duet. A central portion of the rod is embedded in the main body portion. and offset end portions on the rod both proiect from the same side ol the device so that the pivotal mounting may be located on the downstream side of the device whereby in an automobile ventilation system, the pivotal mounting will be on the passenger compartment side of the device, or the side of the device where it is not critical to prevent leakage from the duct.

The flow control device may be molded in a molding apparatus having a first mold portion with a bottom surface for defining one side surface of the elastomeric sealing portion and an edge surface for defining the outer periphery of the sealing portion with a second mold portion surrounded by the first mold portion and having a bottom surface for defining one side surface of the main body portion. A removable mold member receivable in the second mold portion is formed with an edge surface to define the inner periphery of the sealing portion.

The removable mold member is heated to a temperature at or above the temperature to gel plastisol, and is then placed in the molding apparatus. Vinyl plastisol or the like in liquid state is then poured into the first mold portion which surrounds the hot mold member. The hot mold member causes the plastisol to gel on contact, and thus prevents the liquid plastisol from leaking around the removable mold member from the first mold portion to the second mold portion. The liquid plastisol is then partially cured to the extent that the vinyl plastisol becomes non-liquid throughout. The removable moid member is then removed from the assembly and liquid thermosetting epoxy resin is then poured into the second mold portion which is surrounded by the partially cured elastomer. A mounting rod is then placed on the mold with the central portion thereof immersed in the liquid epoxy resin. The mold and the entire contents are then placed in a curing oven or the like to simultaneously cure the epoxy resin and complete curing of the plastisol. The plastisol is thus bonded to the epoxy resin, and the mounting rod is embedded in the solidified epoxy resin.

Other objects, advantages and features of the invention will become apparent from the following description taken in connection with the accompanying drawings in which:

FIG. I is a cross-sectional view of a duct having a flow control device according to the invention mounted therein;

FIG. 2 is a sectional view taken on line 22 of FIG. 1;

FIG. 3 is a plan view of molding apparatus for molding the flow control device shown in H05. 1 and 2;

FIG. 4 is a sectional view taken on line 44 of FIG.

FlG. 5 is a view taken on line 55 of FIG. 3; and

FIGS. 6, 7 and 8 are sectional views similar to FIG. 4 sequentially illustrating the steps in the manufacturing of the control device of FlGSv l and 2.

With reference first to FIGS. 1 and 2, reference numeral 2 collectively designates a flow control device according to the invention in the form of a vane for a butterfly valve or the like, the vane having a main body portion 4 of rigid plastic material, and a sealing portion 6 of elastomeric material on the periphery of the main body portion 4. Mounting means 8 for pivotally mounting the flow control device 2 in a duct 10 comprises a rod molded to the main body portion 4.

The rod 8 has a central portion 12 embedded in the material of the body portion 4, and offset end portions l4 and 16 on the central portion both of which project from one side of the main body portion 4 and through openings in the wall of the duct for pivotally mounting the flow control device 2 in the duct. The central portion 12 has outwardly bent portions 18 and projecting from the main body portion 4, the end portions 14 and 16 extending respectively from the bent portions 18 and 20. A crank arm 22 is formed on the end portion 14 for connection with a cable or similar operating means.

The main body portion 4 of the control device 2 comprises a flat disc with a peripheral flange 24 projecting from one side thereof in the direction of the axis of duct 10. A central bead 26 projects from the same side 23 of the disc forming the main body 4, and the central portion 12 of the mounting rod 8 extends in parallel relationship with the head 26. A bead 28 extending transversely of the bead 26 is also formed on the main body 4 and projects from side 23 thereof. A locating projection 30 is formed on the periphery of the disc or main body 4 for providing vertical support of the main body 4 in the duct 10. As illustrated by reference numeral 32, the edge surface of the disc or main body 4 is inclined outwardly and toward the left as viewed in FIG. 2, and the elastomeric sealing portion 6 is secured to the edge surface 32.

In the embodiment illustrated in FIGS. 1 and 2, the flow control device 2 is of non-circular configuration in plan, and the peripheral sealing portion 6 varies in width around the circumference of the main body 4. The top segment 34 and side segments 36 and 38 of the elastomeric sealing portion 6 are of substantially the same width, while the bottom segment 40 is of substantially less width than segments 34, 36 and 38. The segment 42 of the elastomeric portion adjacent the locating projection 30 is of substantially less width than segment 40. Vertical or axial support of the control device 2 is provided by the locating projection 30 so that the entire periphery of the sealing portion 6 is in good sealing engagement with the inner walls of the duct 10.

The openings in the duct 10 for the end portions 14 and 16 of the mounting rod 8 are on the downstream side of the control device 2 so that there is no likelihood of leakage through such openings on the upstream or high pressure side of the control device 2. The high pressure side is the right hand side of control device 2 in FIG. 2 of the drawings. The end portions 14 and 16 will generally be located on the passenger compartment side of the control device 2 where it is not critical to prevent leakage from the duct 10.

The thin portion 42 of the sealing portion 6 provides a seal beneath the locating projection 30 without a significant amount of deflection of the elastomeric portion 32 so that the upper segment 34 of the sealing portion 6 is in good sealing contact with the upper wall of the duct 10. The mounting rod 8 provides transverse support for the control device 2 such that the side segments 36 and 38 of the sealing portion 6 are in close sealing contact with the respective side walls of the duct. Consequently, when the control device 2 is in the fully closed position illustrated in FIGS. 1 and 2, there will be no flow through the duct past the control device 2.

FIGS. 3, 4 and 5 illustrate molding apparatus for molding the control device 2. Reference numeral 50 collectively designates a mold body having legs 52, 54 and 56. A cavity is formed in the mold body 50 including a first mold portion 58 having a bottom surface 60 for defining one side surface of the sealing portion 6 of the control device 2 and an edge surface 62 for defining the outer periphery of the sealing portion 6. The mold cavity includes a second mold portion 64 surrounded by the first mold portion 58 and having a bottom surface 66 for defining one side surface of the main body portion 4 of the control device 2.

A removable mold member 68 is receivable in the second mold portion 64 and has an edge surface 70 for defining the inner periphery of the sealing portion 6. Transverse recesses 72 and 74 are formed in the bottom surface 66 of the second mold portion 64 for defining the beads 28 and 26, respectively, on the main body portion 4 of the control device 2. The mold portion 64 is also formed with a peripheral recess 76, and the mold member 68 has a corresponding flange 78 projecting from its lower side in FIG. 4 which is receivable in the recess 76.

The bottom surfaces of the first and second mold portions 58 and 64 are non-circular in plan, and the width of the bottom surface of the first mold portion 58 varies around the periphery of the second mold portion 64 in accordance with the configuration of the segments 34, 36, 38, 40 and 42 of the sealing portion 6 of the control device 2. The bottom surface 66 of the mold portion 64 projects outwardly as illustrated at 78 toward the edge surface of the mold portion 58 to define the locating projection of the control device 2.

Rod supporting means is formed on the mold apparatus of FIGS. 3, 4 and 5 and includes a pair of grooves 80 and 82 spaced from each other on opposite sides of the first and second mold portions, grooves 80 and 82 being formed in the rim 84 extending around the periphery of the mold body 50. The rod supporting means further includes a projection 86 extending outwardly from the rim 84 and having a rod receiving recess 88 formed therein which is in axial alignment with the grooves 80 and 82. The projection 86 includes a pair of crank arm locating slots 90 and 92 each communicating with the recess 82 for supporting the crank arm 22 of the mounting rod 8. The slot 90 is used to support a crank arm of one configuration. and the slot 92 is used to support a crank arm of a second configuration. as necessary. The slots 90 and 92 angularly locate the mounting rods with the mold cavity portions 58 and 64. As shown in FIG. 5, when the crank arm of the mounting rod is received in the slot 90, the crank arm comes to rest in a groove 94 formed in the support leg 56 to angularly locate the mounting rod. The mounting rod is indicated in phantom lines at 22a seated in the groove 94. when the slot 92 is used, the crank arm comes to rest in the slot in the location indicated approximately by the phantom lines 22b.

Threadedly mounted in the mold member 68 is a bolt 67 which serves as a handle for lifting the mold member 68 from its position seated in the groove 76 of the mold portion 64. Vent openings 69 are formed in the mold member 68 on opposite sides of the handle 67.

The manufacturing steps are illustrated in sequence in FIGS. 6, 7 and 8. in FIGS. 6, 7 and 8, the main body portion 4 is formed of thermosetting epoxy resin and the sealing portion 6 is formed of plastisol. By plastisol is meant a liquid dispersion of finely divided resin in a plasticizer. It is usually I00 percent solid with no volatiles. and when the volatile content exceeds 5 percent of the total weight, it is referred to as an organosol.

When the plastisol is heated, the plasticizer solvates the resin particles, and the mass gels. With continued application of heat, the mass fuses to become a conventional thermoplastic material.

The removable mold member 68 is first heated to a temperature such that when plastisol comes into contact therewith, sufficient solvation will take place immediately to cause gelation of the plastisol in immediate contact therewith and thus prevent the liquid plastisol from leaking past the edge of the mold member 68. As illustrated in FIG. 6, with the heated mold member 68 mounted on the mold body 50 as shown. vinyl plastisol in liquid state is poured into the mold portion 58. When the liquid vinyl plastisol comes into contact with the hot mold member 68, the plastisol in immediate contact with the mold member 68 promptly gels to prevent leakage of the liquid plastisol around the mold member 68 into the mold portion 64.

The mold 50 along with the hot mold member 68 and the partially gelled liquid plastisol in the mold portion 58 is then further heated either in an oven or by infrared lights to partially cure the plastisol so that the vinyl plastisol becomes solid throughout in the configuration of the sealing portion 6. The removable mold member 68 is generally preheated to a temperature of about 250 which is a temperature substantially above the gelatin temperature of the vinyl plastisol material.

After the vinyl plastisol material 6 of FIG. 6 is partially cured to a solid or non-liquid state, the mold member 68 is removed from the mold body 50. The second mold portion 64 is then filled with liquid epoxy resin as illustrated in FIG. 7. The elevated temperature of the mold body 50 resulting from the partial curing stage of the vinyl plastisol assists in causing the liquid epoxy resin to flow freely into contact with the inner periphery 7 of the partially cured sealing member 6.

The mounting rod 8 is then placed on the mold with the central portion 12 thereof immersed in the liquid epoxy resin. The entire assembly of the mold, mounting rod, partially cured sealing portion 6, and liquid epoxy resin is then placed in a curing oven or the like until the epoxy resin is solidifed and the curing of the vinyl plastisol is completed. The curing temperature of the vinyl and of the epoxy resin is matched so that the curing time is equal for both the sealing portion and the main body portion 4. When curing is complete, the central portion 12 of the mounting rod 8 is embedded in the solidified epoxy resin, and the sealing portion 6 is bonded integrally to the periphery of the main body portion 4. Silicon is baked onto the mold to prevent the epoxy resin from bonding to the mold.

Examples of suitable vinyl plastisol compositions in parts by weight are:

(ill

-Continued Blowing, agent EXAMPLE lll Lopolymcr vinyl resm i003) Vinyl stabilizer (a() l.(] Solvating depressant 4.0 Polymeric plastieirers lrS-BU Monomeric pla ci/crs lS-l IS Diluent plastici/crs S-IS ('film LU Blowing LU While specific embodiments of the invention have been disclosed in the accompanying drawings and described in the foregoing specification, it should be understood that the invention is not limited to the exact construction shown. Alterations in the construction and arrangement of parts, all falling within the scope and spirit of the invention, will be apparent to those skilled in the art.

I claim:

1. A method of making a vane for a butterfly valve or the like wherein the vane has a relatively rigid main body portion and a resilient sealing portion on the periphery of said body portion, said method comprising the steps of: heating a removable mold member to a temperature at or above the temperature required to cause liquid elastomeric material to become solid upon contact therewith; placing the heated mold member into the cavity of a mold having an edge surface for defining the outer periphery of a first mold portion with the periphery of the heated mold member spaced from the edge surface to define the inner periphery of said first mold portion, said first mold portion having a configuration corrcsponding to the configuration of said sealing portion; pouring liquid elastomeric material into the first mold portion; partially curing the elastomeric material in the first mold portion until it becomes non-liquid and hence non-flowable; removing the heated mold member to form a second cavity in said mold surrounded by the partially cured elastomcric material; pouring liquid thermosetting plastic material into the second cavity of the mold such that the liquid thermosetting plastic material flows into contact with the inner periphery of the elastomeric material, placing a pivot rod on the mold in such a manner that the rod extends transversely of the mold and a portion thereof is immersed only in the liquid thermosetting plastic material; exposing the mold with the partially cured elastomeric material, liquid thermosetting plastic material, and pivot rod therein to curing temperature to solidify the thermosetting plastic material with the pivot rod embedded therein and to complete curing of the elastomeric material.

2. The method of claim I wherein the thermosetting plastic material is epoxy resin.

3. The method of claim 1 wherein the elastomeric material is vinyl plastisol.

4. The method of claim 3 wherein the thermosetting plastic material is epoxy resin.

5. In a method of making a vane for a butterly valve or the like wherein the vane has a main body portion of rigid plastic material and a scaling portion of elastomeric material projecting from the periphery of said main body portion, the improvement comprising the steps of: temporarily separating the central portion of a cavity of an open faced mold from the peripheral portion of the cavity by placing a movable preheated mold member into the cavity and against a bottom portion of said mold so that an annular channel is defined becontact with an inner periphery of the partially cured tween said movable mold member and a surrounding elastomeric material; and simultaneously curing the peripheral portion of said mold; pouring liquid elastoresin and completing curing of the elastomeric matemeric material into said annular channel; partially currial. ing the elastomeric material to change it to a non-liquid 6. A method as claimed in claim 5 including the step state by heat from said preheated mold member: reof immersing a portion of a mounting member in the moving the movable mold member from the cavity; liquid resin so that the mounting member is embedded pouring liquid thermosetting resin into the central porin the cured resin. tion of the cavity such that the liquid resin flows into LII 

1. A METHOD OF MAKING A VANE OR A BUTTERFLY ALVE OR THE LIKE WHEREIN THE VANE HAS RELATIVELY RIGID MAIN BODY PORTION AND A RESILIENT SEALING PORTION ON THE PERIPHERY OF SAID BODY PORTION, SAID METHOD COMPRISING THE STEPS OF: HEATING A REMOVABLE MOLD MEMBER TO A TEMPERATURE AT OR ABOVE THE TEMPERATURE REQUIRED TO CAUSE LIQUID ELASTOMERIC MATERIAL TO BECOME SOLID UPON CONTACT THEREWITH, PLACING THE HEATED MOLD MEMBER INTO THE CAVITY OF A MOLD HAVING AN EDGE SURFACE FOR DEFINING THE OUTER PERIPHERY OF A FIRST MOLD PORTION WITH THEPERIPHERY OF THE HEATED MOLD MEMBER SPACED FROM THE EDGE SUFACE TO EFINE THE INNER PERIPHERY OF SAID FIRST MOLD PORTION, SAID FIRST MOLD PORTION HAVING A CONFIGURATION CORRESPONDING TO THE CONFIGURATION OF SAID SEALING PORTION, POURING LIQUID ELASTOMERIC MATERIAL INTO THE FIRST MOLD PORTION, PARTIALLY CURING THE ELASTOMERIC MATERIAL IN THE FIRST MOLD PORTION UNTIL IT BECOMES NON-LIQUID AND HENCE NON-FLOWABLE, REMOVING THE HEATED MOLD MEMBER TO FORM A SECOND CAVITY IN AID MOL SURROUNDED BY THE PARTIALLY CURED ELASTOMERIC MATERIAL, POURING LIQUID THERMOSETTING PLASTIC MATERIAL INTO THE SECOND CAVITY OF THE MOLD SUCH THAT THE LIQUID THERMOSETTING PLASTIC MATERIAL FLOWS INTO CONTACT WITH THE INNER PERIPHERY OF THE ELASTOMERIC MATERIAL, PLACING A PIVOT ROD ON THE MOLD IN SUCH A MANNER THAT THE ROD EXTENDS TRANSVERSELY OF THE MOLD AND A PORTION THEREOF IS IMMERSED ONLY IN THE LIQUID THERMOSETTING PLASTIC MATERIAL, EXPOSING THE MOLD WITH THE PARTIALLY CURED ELASTOMERIC MATERIAL, LIQUID THERMOSETTING PLASTIC MATERIAL, AND PIVOT ROD THEREIN TO CURING TEMPERATURE TO SOLIDIFY THE THERMOSETTING PLASTIC MATERIAL WITH HE PIVOT ROD EMBEDDED THEREIN AND TO COMPLETE CURING OF THE ELASTOMERIC MATERIAL.
 2. The method of claim 1 wherein the thermosetting plastic material is epoxy resin.
 3. The method of claim 1 wherein the elastomeric material is vinyl plastisol.
 4. The method of claim 3 wherein the thermosetting plastic material is epoxy resin.
 5. In a method of making a vane for a butterly valve or the like wherein the vane has a main body portion of rigid plastic material and a sealing portion of elastomeric material projecting from the periphery of said main body portion, the improvement comprising the steps of: temporarily separating the central portion of a cavity of an open faced mold from the peripheral portion of the cavity by placing a movable preheated mold member into the cavity and against a bottom portion of said mold so that an annular channel is defined between said movable mold member and a surrounding peripheral portion of said mold; pouring liquid elastomeric material into said annular channel; partially curing the elastomeric material to change it to a non-liquid state by heat from said preheated mold member: removing the movable mold member from the cavity; pouring liquid thermosetting resin into the central portion of the cavity such that the liquid resin flows into contact with an inner periphery of the partially cured elastomeric material; and simultaneously curing the resin and completing curing of the elastomeric material.
 6. A method as claimed in claim 5 including the step of immersing a portion of a mounting member in the liquid resin so that the mounting member is embedded in the cured resin. 